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Interactive MENG 426 Lab Tutorials Experiment (6) Cast Iron

The American University in Cairo Mechanical Engineering Department MENG 426: Metals, Alloys & Composites. Interactive MENG 426 Lab Tutorials Experiment (6) Cast Iron. Prepared by Eng. Moataz M. Attallah Fall 2002. Outline. Introduction: steel and cast iron Cast iron properties

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Interactive MENG 426 Lab Tutorials Experiment (6) Cast Iron

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  1. The American University in CairoMechanical Engineering DepartmentMENG 426: Metals, Alloys & Composites Interactive MENG 426 Lab Tutorials Experiment (6) Cast Iron Prepared by Eng. Moataz M. Attallah Fall 2002

  2. Outline • Introduction: steel and cast iron • Cast iron properties • Cast iron types • Specimens • Lab report

  3. Ferrous Alloys

  4. CARBON STEELS STAINLESS STEELS ALLOY STEELS Low carbon (Mild) steel 0.3% C Medium carbon 0.3-0.6% C High-carbon >0.6% C Steel Alloys Austenitic Ferritic Martensitic Ppt. Hard. High strength low-alloy HSLA

  5. Effect of Carbon Content

  6. Cast Iron • Carbon content ranging from 2-4.3% • Castable, hard & strong • Wide range of types depending on: • The chemical composition of the iron; the existence of certain alloying elements. • The cooling rate of the casting in the mould. • The type of graphite formed and its percent composition.

  7. Cast Iron Types • Gray (graphite flakes) CI • Malleable CI • Nodular (ductile/spherulitic) CI • White CI

  8. CI Compositions

  9. Pearlitic matrix Graphite flakes Gray (Graphite Flakes) CI • Gray fracture surface • Maximum C% • C precipitate as flakes • High Si% forms flakes • Good wear resistance, vibration damping machineability

  10. Spherulites Pearlitic matrix Ductile (Nodular/spherulitic) CI • C precipitates in black nodules • High fluidity/castability Good machineability Wear resistance • Alloy elements produce nodules

  11. Nodular Cast Iron • Desulfurization • Nodules formation • Inoculation

  12. Cementite Pearlitic matrix White CI • Iron carbide forms instead of iron and graphite • Iron carbide in pearlite • White fracture surface

  13. Pearlitic matrix Graphite clump Malleable CI • Initially formed as white CI • Heat-treated in malleablizing furnace to dissociate Fe3C to iron and graphite • Good wear resistance Ductility Fluidity

  14. Compact CI

  15. Objectives • Focus on the cast iron zone in the iron-iron carbide system. • Get acquainted with the different types of cast irons, and the differences between them in microstructure, mechanical & physical properties. • Study the different microstructures of the different types of cast iron.

  16. Specimens • Gray cast iron • Nodular cast iron • Malleable cast iron • Common grinding and polishing • Etching using 3ml of HNO3 + 100 ml of CH3OH (methyl alcohol), etched by immersing for 15 seconds.

  17. Results • Sketch and describe the microstructure

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